Method of reinforcing a corrugated steel floor panel

ABSTRACT

A method of reinforcing a corrugated steel floor panel comprises the steps of (a) providing a plurality of steel channel sections, each channel section having a length, a rectangular flat central portion with a pair of opposed long sides and a pair of opposed end sides, and a pair of opposed side walls depending downwardly from each of the long sides of the central portion; and (b) placing the channels sections along the corrugations of the floor panel such that the central portion of each channel section is proximate to the upper area of a corrugation and such that the pair of opposed side walls on each channel section depend downwardly towards a base area of a corrugation, and mechanically attaching the central portion of each channel section to an upper area of a corrugation with retainer pins.

FIELD OF THE INVENTION

This invention relates generally to the construction of buildings having a corrugated steel floor panel and, more specifically, to methods of reinforcing such corrugated steel floor panel.

BACKGROUND

Steel framed buildings typically have upper story flooring built upon a corrugated steel floor panel spanning the distances between opposed steel framing beams.

In many situations, especially where the building is being constructed in an earthquake-prone area, the corrugated steel floor panel must be reinforced. In a typical case, the corrugated steel floor panels must be specifically reinforced to withstand sheer forces generated in an earthquake.

One commonly employed method to reinforce a corrugated steel floor panel is to place channel sections over the top of selected corrugations along the steel floor panels and then weld the downwardly depending channel section ends to base areas on either side of the raised corrugation center. However, the procedures involved in properly welding the channel sections over the corrugations are difficult, awkward and expensive.

Accordingly, there is a need for an alternative method of reinforcing a corrugated steel floor panel which avoids these problems inherent in the prior art.

SUMMARY

The invention satisfies this need. The invention is a method of reinforcing a corrugated steel floor panel comprising the steps of (a) providing a plurality of steel channel sections, each channel section having a length, a rectangular flat central portion with a pair of opposed long sides and a pair of opposed end sides, and a pair of opposed side walls depending downwardly from each of the long sides of the central portion; and (b) placing the channels sections along the corrugations of the floor panel such that the central portion of each channel section is proximate to the upper area of a corrugation and such that the pair of opposed side walls on each channel section depend downwardly towards a base area of a corrugation, and mechanically attaching the central portion of each channel section to an upper area of a corrugation with retainer pins.

DRAWINGS

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description, appended claims and accompanying drawings where:

FIG. 1 is a side cut away view of a reinforced corrugated steel panel according to the invention showing a channel section attached to a corrugated panel with retainer pins;

FIG. 2 is a side cut away view of a reinforced steel floor panel according to the prior art showing a steel channel section attached to a corrugated steel floor panel by welding;

FIG. 3 is a front cut away view of a reinforced floor panel, according to the invention, showing a corrugated steel floor panel spanning opposed framing beams and a steel channel section attached to the corrugated steel floor panel with retainer pins;

FIG. 4 is a top front perspective view of a reinforced floor panel according to the invention; and

FIG. 5 is a top side view of the channel section shown in FIG. 4.

DETAILED DESCRIPTION

The invention is a method of reinforcing a corrugated steel floor panel, also referred to as a steel floor system or steel floor assembly. According to the invention, a corrugated steel floor panel is reinforced by mechanically attaching a plurality of steel channel sections to corrugations in the steel floor panel with retainer pins. The invention is a lower cost and faster alternative than traditional methods of reinforcing a corrugated steel floor, which require labor intensive, time consuming, and expensive methods of welding steel.

The following discussion describes in detail one embodiment of the invention and several variations of that embodiment. This discussion should not be construed, however, as limiting the invention to those particular embodiments. Practitioners skilled in the art will recognize numerous other embodiments as well

In steel floor construction, corrugated steel floor panels are supported on steel truss joists or steel beams. The upper surface of the steel floor is constructed by fastening corrugated steel panels to floor trusses and beams. According to the invention, a method of reinforcing a corrugated steel floor panel is provided. FIG. 1 is a side cut away view of a reinforced floor panel 10, according to the invention, where a steel channel section 12 is attached to a corrugated floor panel 14 with retainer pins 16 a and 16 b. The corrugated floor panel 14 is attached to a steel beam 18, by methods known to those of skill in the art.

FIG. 2 is a side cut away view of a reinforced floor panel 20, according to the prior art, where a steel channel section 22 is attached to a steel beam 28 and to a corrugated steel panel 24 by a weld 26 a and 26 b.

Referring now to FIG. 3 a, FIG. 3 a is a front cut away view of the reinforced floor panel 10 shown in FIG. 1. FIG. 3 a shows a corrugated steel floor panel 14 spanning opposed framing beams 18 a and 18 b and a steel channel section 12 attached to the corrugated steel floor panel 14 with retainer pins 16 is shown. FIG. 3 a is shown as an example of a corrugated steel floor panel 14 spanning an opposing steel beam 18 and a framing column or wall 19. However, the invention can also be used to reinforce other steel construction such as steel roofing panels, and can be used to reinforce steel panels spanning opposing beams, girders, columns, joists and trusses, as will be understood by those of skill in the art.

Referring now to FIG. 3 b, FIG. 3 b is a front cut away view of the prior art reinforced floor panel 20 shown in FIG. 2, which shows a corrugated steel floor panel 24 spanning opposed framing beams 28 a and 28 b and a steel channel section 22 attached to the corrugated steel floor panel 24 with a welded seam 26. As shown in FIG. 3 b, the prior art reinforced corrugated steel floor panel requires a welded seam 26 that runs the length of the channel section 22, a labor intensive and expensive reinforcement process.

Referring now to FIG. 4 and FIG. 5, FIG. 4 is a top side view of a reinforced floor panel according to the invention, and FIG. 5 is a top front side view of the channel section shown in FIG. 4. As shown in FIG. 4, the corrugated steel floor panel 30 has a plurality of corrugations (32 a, 32 b, 32 c, and 32 d), each corrugation has a length 34, a generally horizontal first base area 36, a generally horizontal second base area 38, a first riser wall 40, a second riser wall 42, and a generally horizontal upper area 44. The first base area 36 and the second base area 38 are disposed at substantially the same base elevations and the upper area 44 is disposed at an upper elevation greater than the base elevation. The corrugated steel floor panel 30 is reinforced with one or more steel channel sections 46, each channel section 46 having a length 48, a rectangular flat central portion 50 with a pair of opposed long sides 52 a and 52 b and a pair of opposed end sides 54 a and 54 b, and a pair of opposed side walls 56 a and 56 b depending downwardly from each of the long sides of the central portion 50. As shown in FIG. 4, the corrugated steel floor panel 30 is reinforced by placing at least one channel section 46 along a corrugation 32 of the floor panel 30 such that the central portion 50 of each channel section 46 is in contact with the upper area 44 of a corrugation 32 and such that the pair of opposed side walls 56 a and 56 b on each channel section 46 depend downwardly and are in contact with a first base area 36 and a second base area 38 of a corrugation. The central portion 50 of each channel section 46 is mechanically attached to an upper area of a corrugation 32 with a plurality of retainer pins 58.

Referring again to FIG. 4 and FIG. 5, in the invention, the method comprises providing a plurality of steel channel sections 46, each channel section 46 having a length 48, a rectangular flat central portion 50 with a pair of opposed long sides 52 a and 52 b and a pair of opposed end sides 54 a and 54 b, and a pair of opposed side walls 56 a and 56 b depending downwardly from each of the long sides of the central portion. Then, a channel section 46 is placed along corrugations 32 of the floor panel 30 such that the central portion of each channel section 50 is in contact with the upper area of a corrugation 32 and such that the pair of opposed side walls 56 a and 56 b on each channel section 46 depend downwardly and at least a portion of the opposed side walls 56 a and 56 b are in contact with the first and second base areas 36 and 38 of a corrugation. The central portion 50 of each channel section 46 is then and mechanically attached to an upper area of a corrugation 32 with a plurality of retainer pins 58.

The channel sections 12, 46 are chosen such that the central portion of each channel section is only slightly larger than the horizontal upper area 44 of the corrugations 32 and such that the pair of opposed end sides 56 a and 56 b matches the height of the first riser wall 40 and the second riser wall 42 of the corrugations 32. Using such channel sections 12, 46 in the invention assures that, when a channel section 12, 46 is placed along a corrugation 32, the central portion 50 of the channel section 12, 46 is in contact with the upper area 44 of the corrugation 32 and at least a portion of the opposed side walls 56 a and 56 b are in contact with the first and second base areas 36 and 38 of a corrugation. Appropriate channel sections are known to those of skill in the art.

The fitness of the central portion 50 and side walls 56 a and 56 b of the channel section are chosen to provide sufficient strength, depending upon the particular construction situation in which the method is employed. Further, the channel sections 46 are placed on selected corrugations 32 and on selected locations as necessary to meet strength requirements depending upon the construction situation for which the invention is employed, as will be understood by those of skill in the art by reference to this disclosure.

The retainer pins 16 used to mechanically attach the central portion 50 of each channel section 12, 46 are typically retainer pins driven through the central portion 50 of each channel section 12, 46 and the central portion 50 of the corrugation 14, 32 by an explosive charge, such as the charge provided by a 22-caliber shell. An example of a corrugated steel floor panel usable in the invention is a 6×13 steel channel section. Retainer pins may be nails, or threaded stud studs, with various shank diameters, thread diameters, lengths, and knurled or smooth shanks, and may be coated or plated. Preferred retainer pins useable in the invention can be obtained from Hilti Corporation of Liechtenstein (hilte.com) as Hilti X-EDN19THQ 12 shot pins. The pins can be driven through the central portion of each channel section and the upper area of each corrugation by powder actuated fastening tools commonly known in the trade and marketed by, for example, Hilti Corporation of Liechtenstein.

The pins are driven through the central portion 50 of each channel section in a suitable pattern, according to safety standards and manufacturer specifications. For example, when Hilte Hilte X-EDN19THQ 12 shot pins are used, preferably, the pins are attached to the central portion 50 of each channel section 12, 46 in a stagger pattern, as shown below, with a maximum of about 5 inches between each pin and a maximum of about 5 inches between the rows of pins (i.e., @ 5″ O.C. Max Stagg), The minimum spacing between pins is preferably about 1½ inches between each pin and about 1½ inches between the rows of pins, and the minimum edge distance is about ½ inch.

However, other configurations may be used to attach the central portion 50 of each channel section 12, 46 to each corrugation 14, 32, with retainer pins, as will be understood by those of skill in the art.

The invention provides a reinforced corrugated steel floor plan having all of the strength and resistance to sheer forces as corrugated steel floor panels reinforced with welded channel sections, but can be typically constructed in ______% less time[INSERT DATA]. Further, welding channel sections requires highly trained and expensive welders. In contrast, the mechanical attachment of the channel section 12, 32 with retainer pins 16 to a corrugation section 14, 32 may be done by less trained laborers, thus significantly reducing the construction costs.

Having thus described the invention, it should be apparent that numerous structural modifications and adaptations may be resorted to without departing from the scope and fair meaning of the instant invention as set forth hereinabove. 

1. A method of reinforcing a corrugated steel floor panel having a plurality of corrugations, each corrugation having a length, a generally horizontal first base area, a first riser wall, a generally horizontal upper area, a second riser wall and a second base area, the first base area and the second base area being disposed at substantially the same base elevation and the upper area being disposed at an upper elevation greater than the base elevation, the method comprising the steps of: (a) providing a plurality of steel channel sections, each channel section having a length, a rectangular flat central portion with a pair of opposed long sides and a pair of opposed end sides, and a pair of opposed side walls depending downwardly from each of the long sides of the central portion; and (b) placing the channels sections along corrugations of the floor panel such that the central portion of each channel section is in contact with the upper area of a corrugation and such that the pair of opposed side walls on each channel section depend downwardly and are in contact with the base area of a corrugation, and mechanically attaching the central portion of each channel section to an upper area of a corrugation with retainer pins.
 2. The method of claim 1 wherein the retainer pins are mechanically attached to each steel channel section in a scatter pattern.
 3. The method of claim 2 wherein the scatter pattern is between about 1½ inches to about 5 inches between each pin and between about 1½ inches to about 5 inches between each row of pins.
 4. The method of claim 1 wherein the retainer pins are mechanically attached to the central portion of each steel channel section and to the upper area of the corrugation with a powder actuated fastening tool.
 5. The method of claim 1 wherein only a portion of at least one of the corrugations is reinforced with a steel channel section.
 6. A method of reinforcing a corrugated steel floor panel with retainer pins, the method comprising: (a) providing a corrugated steel floor panel, the steel floor panel having a plurality of corrugations; (b) providing a steel channel section, and (c) mechanically attaching the steel channel section to a corrugation with a plurality of retainer pins.
 7. The method of claim 6 wherein the retainer pins are mechanically attached to each steel channel section in a scatter pattern.
 8. The method of claim 7 wherein the scatter pattern is between about 1½ inches to about 5 inches between each pin and between about 1½ inches to about 5 inches between each row of pins.
 9. The method of claim 6 wherein the retainer pins are mechanically attached to the central portion of each steel channel section and to the upper area of the corrugation with a powder actuated fastening tool.
 10. The method of claim 6 wherein only a portion of at least one of the corrugations is reinforced with a steel channel section. 